Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Removal lever -80 - 200-

t	Used oil collection and extraction unit -V.A.G 1782-

t	Stepladder -VAS 5085-

t	Engine bung set -VAS 6122-

t	Scissor-type assembly platform -VAS 6131 A- with support set for Audi -VAS 6131/10- and support set -VAS 6131/11-, -VAS 6131/13- and 3x -VAS 6131/10-2-

t	Drip tray for workshop hoist -VAS 6208-

t  Hose clip pliers -VAS 6340-

t  Hose clip pliers -VAS 6362-

t  Puller -T40160- Procedure   WARNING Make sure the vehicle cannot tip over when the engine is removed. Secure the vehicle, to do so, the luggage compartment must be empty. The fuel system operates at extremely high pressure. This can cause injury. The fuel pressure in the high-pressure section of the injection system must be reduced to a residual pressure prior to opening the system. –  Reduce fuel pressure in high-pressure section of injection system → Rep. gr.24.   Note The electromechanical parking brake must be released before disconnecting the battery, so that the propshaft can be turned during removal.

–  Set front wheels to straight-ahead position.   Caution Electronic components are susceptible to damage. Observe notes on procedure for disconnecting the battery. –  Switch off ignition and take out ignition key. –  Disconnect earth wire -2- from battery terminal → Electrical system; Rep. gr.27. –  Discharge refrigerant system → Air conditioner with refrigerant R134a. –  Extract hydraulic fluid for power steering from reservoir using used oil collection and extraction unit -V.A.G 1782-.

–  Remove engine cover panel -arrows-.

WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. –  Remove both front wheels → Wheels and tyres; Rep. gr.44. –  Remove front left and front right wheel housing liners → Rep. gr.66.

–  Remove noise insulation panels -1- and -2- → Rep. gr.66.

–  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Unscrew drain plug -arrow- on coolant pipe (front) and drain off coolant.

–  Unscrew drain plug -arrow- on map-controlled engine cooling system thermostat -F265- and drain off coolant.

–  Pull out retaining clip -2- and disconnect coolant hose from radiator.   Note Disregard -items 1, 3, 4-.

–  Detach vacuum hose -1- and move hydraulic hose -arrow- clear at bracket. –  Unscrew nuts -2- and detach vacuum reservoir.

–  Position used oil collection and extraction unit -V.A.G 1782- below connection point. –  Disconnect hydraulic fluid supply hose -2- and return hose -1- for power steering. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

Caution Danger of damage to refrigerant lines and hoses. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Remove bolts -1- and -2-. –  Disconnect refrigerant lines from A/C compressor. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Unscrew nut -arrow- on longitudinal member (right-side) and move earth cables clear.

–  Unplug electrical connector -2-. –  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Disconnect coolant hoses from continued coolant circulation pump -V51--arrows-.   Note Disregard -item 1-.

–  Unplug electrical connector -3- at secondary air pump motor -V101- and move electrical wiring clear. –  Disconnect hose -1- for secondary air system and move clear.   Note Disregard -item 2-.

–  Unplug electrical connectors -1- and -2- for radiator fan (push retainer to the rear -arrow- and press down release catch). –  Move clear electrical wiring harness.

–  Remove bolts -1- and nuts -3- on both sides and detach struts for lock carrier -2-.

WARNING Risk of injury caused by fuel. To allow the fuel pressure to dissipate, wrap a clean cloth around the connection and carefully loosen the connection before opening the fuel system.   Caution Observe rules for cleanliness when working on the fuel supply system → Chapter. –  Disconnect fuel line -arrow-.

–  Move clear fuel line and line going to activated charcoal filter at air pipe. –  Unplug electrical connector -2- at activated charcoal filter solenoid valve 1 -N80- and detach vacuum hose -1-. –  Detach activated charcoal filter solenoid valve 1 -N80- from bracket and move to one side with hose and fuel line still attached.

USA models: –  Disconnect vacuum hose leading to fuel system diagnostic pump -V144--arrow-.

All vehicles (continued): –  Remove air duct -arrow-.

–  Unplug electrical connector -1- from air mass meter -G70-. –  Disconnect vacuum line -3- from air pipe. Rest-of-world vehicles: –  Disconnect crankcase breather hose -2- from air pipe by pressing release tabs. –  Remove air pipe and air mass meter -G70-. To do so, release hose clip -4- and clamps -arrows-. USA models:   Caution Risk of violating emission legislation applying to USA models. Do NOT open hose connection -2-. –  Move air pipe clear to one side (crankcase breather hose -2- remains connected). To do so, release hose clip -4- and clamps -arrows-.

All vehicles (continued): –  Disconnect vacuum line -1-. –  Detach air cleaner housing and unplug electrical connector -2- at variable intake manifold change-over valve -N335- on reverse side of air cleaner. –  Disconnect hose -3- for secondary air system.

–  Lift retaining clip -2-, release hose clip -1- on coolant pipe (right-side) and remove coolant hose.

–  Unplug electrical connector -1- for vacuum pump for brakes -V192- and move wiring clear. –  Disconnect vacuum hose -2-.

–  Disconnect coolant hoses -1- and -3- from coolant expansion tank.   Note Ignore items marked -2- and -arrows-.

–  Remove seal -arrow-. –  Remove plenum chamber cover → Rep. gr.50.

–  Release retainer -arrow A- and open cover -arrow B-.

–  Remove nuts -1- and -2- for electrical wiring. –  Unplug electrical connectors -3- and -4- and move clear. –  Remove bolt -5- and detach terminal 30 wiring junction 2 -TV22- from body brace -arrow-.

–  Working from wheel housing, release catches using a 5.5 mm ring spanner -item 1- and remove wiring protector -2- from above. –  Release wiring harness -3- leading to alternator and starter using removal lever -80 - 200- and move clear.

–  Release catch -arrow B-, pull wiring duct forwards -arrow A- and move clear.

–  Remove nut -1- and swivel filler neck for washer fluid reservoir slightly upwards -arrow A-. –  Pull filler neck -2- with filler pipe out of washer fluid reservoir and through opening in body -arrow B-.

–  Remove bolts -1- and nuts -2- and detach body brace -3- (different types may be fitted depending on version).

–  Remove bolts -arrows- and detach cover for electronics box in engine compartment. –  Remove nut -1- and move electrical wiring clear.

–  Release catches -arrows A- and take out engine control unit -arrow B-.

–  If fitted, unplug electrical connector -2-. –  Unplug electrical connectors -4- and unscrew nut -3- for wiring. –  Release catches -arrow- and detach relay carrier with fuse holder -1-. –  Disengage engine wiring harness at electronics box in engine compartment and move clear.

–  Release catches -arrows A- and detach wiring protector -2--arrow B-. –  Unscrew earth stud -1- and move earth wiring clear. –  Place wiring harness on engine and secure engine control unit to prevent it from dropping.

–  Mark coolant hoses -1- and -2- for later installation and disconnect hoses. –  Push coolant hoses with hose protector through into engine compartment.

–  Unplug electrical connectors -arrow- at front wheel speed sensors on both sides.

–  Unplug electrical connector -1- on headlight range control sender 1 -G233- and release wiring -arrow-.

–  Release electrical connector -2- at bracket by pulling retainer catch to the rear -arrow A- and turning connector approx. 90° in direction of -arrow B-. –  Move clear electrical wire -3- and brake hose -4- at bracket. –  Remove bolts -1- and tie up brake caliper in wheel housing with wire (brake line remains attached).   Caution Avoid damage to brake pistons. Do not operate brake pedal with brake caliper removed.

–  Remove nut -2- and pull out bolt -1-. –  Pull upper suspension links upwards out of wheel bearing housing -arrows-. –  Perform the same work steps on the other side of the vehicle.

Vehicles up to vehicle identification no. 8T-8A-011200: –  Remove bolt -3- for anti-roll bar on both sides. –  Remove nut -1- on both sides.   Note The bolts -2- are removed at a later stage.

Vehicles from vehicle identification no. 8T-8A-011201 onwards: –  Remove bolt -1- for anti-roll bar on both sides. –  Remove nut -3- on both sides.   Note The bolts -2- are removed at a later stage.

All vehicles (continued):   Caution Risk of damage to running gear components. The vehicle must NOT be lowered onto its wheels if the engine/gearbox mountings, steering box or subframe cross brace are not properly installed. –  Remove subframe cross brace → Rep. gr.40.

–  Remove bolts -arrows- and detach front cross member.

–  Unscrew nuts -arrows- for front silencer (left-side).

–  Unscrew nuts -arrows- for front silencer (right-side).

Caution Risk of damage to flexible joints in front silencer. Do NOT bend the flexible joints in the front silencer more than 10°. –  Loosen and push back clamps -1- and -2- and detach front silencers on both sides.

–  Remove bolts -arrows- and detach heat shield -1- for propshaft.

–  Remove propshaft from gearbox → Rear final drive 0AR and 0BC; Rep. gr.39. –  Slide propshaft towards rear final drive; the constant velocity joints can be moved axially. –  Tie up propshaft on one side.

–  Detach intermediate steering shaft from steering box and move clear by telescoping upwards → Rep. gr.48.

–  Remove bolt -2- and tie up clutch slave cylinder at side of engine compartment.   Caution Avoid damage to clutch slave cylinder. Do not press clutch pedal after removing slave cylinder. –  Remove nut -1- for selector rod.

–  Apply puller -T40160- and pull off selector rod -1-.

Set up the scissor-type assembly platform as follows: –  Set up scissor-type assembly platform -VAS 6131 A- with support set for Audi -VAS 6131/10- and supplementary set -VAS 6131/13- as follows:

Platform coordinates	Parts of support set for Audi -VAS 6131/10- and supplementary set -VAS 6131/13-
B4	/13-4	/10-4	/10-5	/13-1
G4	/13-4	/10-4	/10-5	/13-1
B6	/10-1	/10-2	/10-5	/10-11
G6	/10-1	/10-2	/10-5	/10-11
A8+C8	/13-6			/13-2
F8+H8	/13-6			/13-2
C14	/10-1	/10-3	/10-5	/10-13
F14	/10-1	/10-3	/10-5	/10-10

–  Initially hand-tighten the support elements on the scissor-type assembly platform. –  Position scissor-type assembly platform -VAS 6131 A- horizontally. l  Take note of spirit level (bubble gauge). –  Position scissor-type assembly platform -VAS 6131 A- below engine/gearbox assembly.

WARNING Accident risk if subframe mountings are detached. Subframe bolts -2- and -3- must not be loosened. –  Remove subframe bolts -1- on both sides.

–  Position support elements from -VAS 6131/10- and -VAS 6131/13- at front left and right of subframe as shown. –  Make sure that threaded spindles are screwed in completely.

–  Position support elements from -VAS 6131/10- (rear left and right) at front attachment points of subframe cross brace as shown.

–  Position support elements from -VAS 6131/13- under left and right wheel bearing housings as shown.

–  Detach retaining clips for noise insulation from cross member. –  Position support elements from -VAS 6131/10- at rear of cross member on both sides, as shown in illustration. –  Turn all spindles for support elements upwards until all locating lugs make contact with mounting points. –  Tighten base plates for support elements to 20 Nm on scissor-type assembly platform -VAS 6131 A-.

–  Mark installation position of subframe and tunnel cross member on longitudinal members with felt-tip pen. –  Unscrew subframe bolts -2- and -3- on both sides in several stages and in diagonal sequence.   Note Disregard -item 1-.

–  Remove bolts -arrows- and detach tunnel cross member.

Vehicles up to vehicle identification no. 8T-8A-011200: –  Remove bolt -2- on both sides.

Vehicles from vehicle identification no. 8T-8A-011201 onwards: –  Remove bolt -2- on both sides. All vehicles (continued):   Caution Danger of damage to hoses, pipes and wiring connections and to engine compartment. t  Check that all hoses and wiring connections between engine, gearbox, subframe and body have been detached. t  Carefully guide out engine/gearbox assembly with subframe from engine compartment when lowering.

–  Lower engine/gearbox assembly using scissor-type assembly platform -VAS 6131 A- initially only as far as distance -a-. l  Dimension -a- = 100 mm (maximum).

–  Remove bolts -1- and -3- for selector rod and push rod.   Note Disregard -item 2-. –  Lower engine/gearbox assembly further. –  Pull out scissor-type assembly platform -VAS 6131 A- with engine/gearbox assembly from underneath vehicle.